Assembler for assembling a carrier for printhead integrated circuits

ABSTRACT

Provided is an assembler for assembling a carrier for supporting printhead integrated circuits. The carrier has upper and lower parts that are operatively fastened together. The assembler includes a support structure configured to support the lower part in a pre-fastened position, and a holding mechanism arranged on the support structure for holding the upper part in a pre-fastened position. The assembler also includes a displacement mechanism arranged on the support structure for displacing the holding mechanisms to bring the parts into operative registration with each other, and a fastening apparatus for fastening the parts together.

FIELD OF THE INVENTION

The invention relates to an assembler for assembling a carrier forsupporting printhead integrated circuits, a method for assembling acarrier for integrated circuits, a safety system for an assemblingapparatus for assembling a circuitry test support, a carriage assemblyfor use with an assembling apparatus of an integrated circuit carrier,and an adhesive application apparatus for use with an assembling machinefor assembling a carrier for printhead integrated circuits.

CO-PENDING APPLICATIONS

The following applications have been filed by the Applicantsimultaneously with the present application:

MPN023US MPN024US MPN025US MPN026US MPN027US MPN028US MPN029US MPN030USMPN031US MPN032US MPN033US MPN034US MPN035US MPN036US MPN037US MPN038USMPN039US MPN041US MPN042US MPN043US MPN046US MPN047US MPN049US MPN051USMPN052US MPN053US MPN054US MPN055US MPN056US MPN057US MPN058US MPN059USMPN060US MPN061USThe disclosures of these co-pending applications are incorporated hereinby reference. The above applications have been identified by theirfiling docket number, which will be substituted with the correspondingapplication number, once assigned.

CROSS REFERENCES

The following patents or patent applications filed by the applicant orassignee of the present invention are hereby incorporated bycross-reference.

11/246687 11/246718 7322681 11/246686 11/246703 11/246691 11/24671111/246690 11/246712 11/246717 7401890 7401910 11/246701 11/24670211/246668 11/246697 11/246698 11/246699 11/246675 11/246674 11/24666711/829957 11/829960 11/829961 11/829962 11/829963 11/829966 11/82996711/829968 11/829969 11946839 11946838 11946837 11951230 1214103412140265 12183003 11/688863 11/688864 11/688865 7364265 11/68886711/688868 11/688869 11/688871 11/688872 11/688873 11/741766 1201476712014768 12014769 12014770 12014771 12014772 12014773 12014774 1201477512014776 12014777 12014778 12014779 12014780 12014781 12014782 1201478312014784 12014785 12014787 12014788 12014789 12014790 12014791 1201479212014793 12014794 12014796 12014798 12014801 12014803 12014804 1201480512014806 12014807 12049371 12049372 12049373 12049374 12049375 1210367412146399

BACKGROUND OF THE INVENTION

Pagewidth printers that incorporate micro-electromechanical componentsgenerally have printhead integrated circuits that include a siliconsubstrate with a large number of densely arrangedmicro-electromechanical nozzle arrangements. Each nozzle arrangement isresponsible for ejecting a stream of ink drops.

In order for such printers to print accurately and maintain quality, itis important that the printhead integrated circuits be tested. This isparticularly important during the design and development of suchintegrated circuits.

Some form of carrier is generally required for testing such integratedcircuits.

SUMMARY OF THE INVENTION

According to one aspect of the invention there is provided an assemblerfor assembling a carrier for supporting printhead integrated circuits,said carrier having upper and lower parts that are operatively fastenedtogether, said assembler comprising:

a support structure configured to support the lower part in apre-fastened position;

a holding mechanism arranged on the support structure for holding theupper part in a pre-fastened position;

a displacement mechanism arranged on the support structure fordisplacing the holding mechanisms to bring the parts into operativeregistration with each other; and

a fastening apparatus for fastening the parts together.

The support structure may include a support bed and a carriage assemblypositioned on the support bed, the displacement and holding mechanismsbeing arranged on the carriage assembly.

The carriage assembly may have a linear carriage spaced from the supportbed and carriage actuators for linear displacement of the holdingmechanisms with respect to the support bed.

The fastening apparatus may include an operatively lower clamp and anoperatively upper clamp, the clamps being configured to correspond withthe lower part and the upper part respectively to clamp the partstogether, the support bed being configured to support the lower clamp ina pre-clamped position.

The fastening apparatus may include an upper clamp lifting and holdingmechanism arranged on the carriage assembly and configured to lift theupper clamp from the support bed and to bring it into operativeengagement with the lower clamp.

The fastening apparatus may include an adhesive dispenser arranged onthe support structure and configured to dispense an adhesive to beapplied to one of the parts.

The fastening apparatus may include an adhesive applicator positioned onthe support bed to receive adhesive dispensed by the dispenser, thedisplacement mechanism being configured to displace the upper part intoengagement with the applicator prior to positioning the upper part onthe lower part.

The upper clamp lifting and holding mechanism may be configured to bringthe upper clamp into operative engagement with the lower clampsubsequent to positioning the upper part on the lower part.

According to a second aspect of the invention, there is provided amethod for assembling a carrier for integrated circuits, said carrierhaving upper and lower parts, the method comprising the steps of:

positioning the lower part in a bottom clamp portion retained in abottom clamp receptacle;

positioning a top clamp portion in a top clamp receptacle, the clampportions being configured to engage each other in a locking manner;

positioning the upper part in a first gripper;

applying adhesive to at least one of the parts;

pressing said upper part onto the bottom part retained by the bottomclamp receptacle with the first gripper, whilst retrieving the top clampportion with a second gripper; and

locking the top clamp portion to the bottom clamp portion with thesecond gripper to clamp the parts together.

The step of positioning the carrier parts may include positioningcarrier parts molded from a liquid crystal polymer (LCP). The step ofpositioning the carrier parts may include receiving carrier parts whichdefine a plurality of discrete fluid paths when operatively joined toform a fluid supply carrier for the printhead circuitry.

The step of applying adhesive may include dispensing the adhesive withan adhesive dispenser onto a surface and dipping at least part of thegripped upper part in such dispensed adhesive with said first gripper.

The method may be carried out with an apparatus that defines asingle-user station and including the step of monitoring an operationalstatus of the apparatus.

The method may include the step of reading identifiers on the carrierparts and relaying data representing the identifiers to a control systemof the apparatus.

According to a third aspect of the invention there is provided a safetysystem for an assembling apparatus for assembling a circuitry testsupport having a number of components to be fastened together, theapparatus having moveable mechanisms displaceable within an operatingzone, the system comprising:

a sensor arrangement for sensing an operational status of the assembler;

an emergency cut-off mechanism operatively connected to the sensorarrangement and configured to deactivate the assembler when an undesiredoperational status is sensed; and

a control system for controlling operation of the sensor arrangement andthe emergency cut-off mechanism.

The control system may be configured such that the operational statusincludes aspects selected from the group consisting of: a position ofthe movable mechanisms; a presence of a foreign object proximate themovable mechanisms; a fluid pressure of hydraulic or pneumatic actuatorsof the movable mechanisms; a presence of the components; authenticity ofthe components; an electricity supply to the assembler; and an operatoridentifier of an operator operating the assembler.

Accordingly, the sensor arrangement may include a plurality ofmicro-switches for sensing positions of the movable mechanisms. Thesensor arrangement may include a light curtain connected to the controlsystem to detect the ingress of a foreign object into the operatingzone, a pressure sensor connected to the control system to detect afluid pressure of hydraulic or pneumatic actuators for the movablemechanisms and proximity sensors connected to the control system todetect a position of the components.

The sensor arrangement may include a barcode scanner connected to thecontrol system and operable to scan a barcode of the components toenable verification of the authenticity of the components by the controlsystem.

The control system may be configured to communicate with a remotemonitoring system.

According to a fourth aspect of the invention, there is provided acarriage assembly for use with an assembling apparatus used to assembleoperatively upper and lower portions of an integrated circuits carrierwith co-operative upper and lower clamping members, the carriageassembly comprising:

a linear carriageway in a working zone of the assembling apparatus andspaced from a support surface of the apparatus;

a first holding mechanism movable along the linear carriageway andconfigured to hold the upper carrier portion and to displace said upperportion substantially orthogonally with respect to said linearcarriageway towards and away from a support surface of the assemblingapparatus;

a second holding mechanism movable along the linear carriage andconfigured to hold the upper clamping member and to displace the upperclamping member towards and away from the support surface;

a linear actuator configured to displace the holding mechanisms alongthe carriageway; and

a control system to control operation of the holding mechanisms and thelinear actuator.

The control system may be configured to displace the first holdingmechanism through an operative cycle that includes a first step towardsthe support surface, a second step away from the support surface, athird step along the carriageway, a fourth step towards the supportsurface and a fifth step away from the support surface.

The control system may be configured to displace the second holdingmechanism through an operative cycle that includes a first step alongthe carriageway, a second step towards the support surface, a third stepaway from the support surface, a fourth step along the carriageway in adirection opposite to the first step, a fifth step back towards thesupport surface and a sixth step away from the support surface.

The first and second holding mechanisms may be fast with each other suchthat the third step of the first holding mechanism is simultaneous withthe first step of the second holding mechanism.

The control system may be configured to displace the first holdingmechanism such that the upper portion is brought into and out ofoperative engagement with an adhesive station on the support surface inthe first and second steps, into alignment with the lower portionpositioned in the lower clamp member on the support surface in the thirdstep and into adhesive engagement with the lower portion in the fourthstep.

The control system may be configured to displace the second holdingmechanism into alignment with the upper clamp member in the first step,into engagement with the upper clamp member in the second step, awayfrom the support surface, with the upper clamp member, in the thirdstep, into alignment with the upper portion in the fourth step, toengage the upper clamp member with the lower clamp member in the fifthand to disengage from the upper clamp member in the sixth step.

According to a fifth aspect of the invention, there is provided anadhesive application apparatus for use with an assembling machine forassembling operatively upper and lower components for carrying printheadintegrated circuits, the application apparatus comprising:

a plate;

a dispensing mechanism which includes an adhesive reservoir, saidmechanism being operatively engaged with said plate in a sealing andsliding manner, the mechanism configured to dispense adhesive onto theplate when sliding along the plate;

a displacement mechanism to slide the dispensing mechanism along theplate; and

a control system to control operation of the dispensing and displacementmechanisms.

The dispensing mechanism may be configured to dispense adhesiveaccording to a pad printing technique. The plate may define an etchedchannel shaped and dimensioned according to the upper component, so thata particular part of the upper component is covered in adhesive when theportion is placed on the plate.

The displacement mechanism may include a linear carriage and actuatorengaged with the dispensing mechanism. The dispensing mechanism mayinclude a dispensing cup in which adhesive is stored, the dispensing cupbeing magnetically attracted to the plate to generate said operativeengagement.

According to a sixth aspect of the invention, there is provided asoftware product for execution by a processor of an assembler forassembling a carrier operatively supporting a printhead integratedcircuit, said software product enabling the processor to perform thesteps of:

positioning a lower carrier part in a bottom clamp portion retained in abottom clamp receptacle;

positioning a top clamp portion in a top clamp receptacle, the clampportions being configured to engage each other in a locking manner;

positioning an upper carrier part in a first gripper;

applying adhesive to at least one of the parts;

pressing said upper part onto the bottom part retained by the bottomclamp receptacle with the first gripper, whilst retrieving the top clampportion with a second gripper; and

locking the top clamp portion to the bottom clamp portion with thesecond gripper to clamp the parts together.

According to a seventh aspect of the invention, there is provided memorycomprising a software product for execution by a processor of anassembler for assembling a carrier operatively supporting a printheadintegrated circuit, said software product enabling the processor toperform the steps of:

positioning a lower carrier part in a bottom clamp portion retained in abottom clamp receptacle;

positioning a top clamp portion in a top clamp receptacle, the clampportions being configured to engage each other in a locking manner;

positioning an upper carrier part in a first gripper;

applying adhesive to at least one of the parts;

pressing said upper part onto the bottom part retained by the bottomclamp receptacle with the first gripper, whilst retrieving the top clampportion with a second gripper; and

locking the top clamp portion to the bottom clamp portion with thesecond gripper to clamp the parts together.

The invention is now described, by way of example, with reference to theaccompanying drawings. The following description is intended toillustrate particular embodiments of the invention and to permit aperson skilled in the art to put those embodiments of the invention intoeffect. Accordingly, the following description is not intended to limitthe scope of the preceding paragraphs or the claims in any way.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 shows a frontal layout view of an embodiment, in accordance withthe invention, of an assembler for a carrier for supporting printheadintegrated circuits;

FIG. 2 shows a perspective view of a holding mechanism for an uppercarrier part of the assembler of FIG. 1;

FIG. 3 shows a perspective view of a holding mechanism for an upperclamp of the assembler of FIG. 1;

FIG. 4 shows an exploded perspective view of the upper part and a lowercarrier part of the carrier for supporting printhead integratedcircuits;

FIG. 5 shows a perspective view of an embodiment, in accordance with theinvention, of an adhesive application apparatus for use with anassembling machine for assembling operatively upper and lower componentsfor carrying printhead integrated circuits, which can be the assemblerof FIG. 1;

FIG. 6 shows a perspective view of a displacement mechanism of theassembler shown in FIG. 1;

FIG. 7 shows a perspective view of an upper clamp lifting and holdingmechanism of the assembler shown in FIG. 1;

FIG. 8.1 shows electrical and pneumatic components in an enclosure forthe assembler of claim 1;

FIG. 8.2 shows a side view of the enclosure of FIG. 8.1, showingexternal connections for the electrical and pneumatic components;

FIG. 9 shows an exploded detailed view of a fastening apparatus of theassembler of FIG. 1 for fastening the upper and lower carrier partstogether;

FIG. 10 shows an embodiment of a user interface for the assembler ofFIG. 1;

FIG. 11 shows an embodiment of a foot switch forming part of a userinterface for the assembler of FIG. 1; and

FIG. 12 shows a flow diagram representing a method, in accordance withthe invention, for assembling the carrier for integrated circuits.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the accompanying drawings, reference numeral 10generally refers to an assembler or assembling machine for assembling acarrier for supporting printhead integrated circuits, in accordance withthe invention. Throughout this description, like reference numeralsindicate like components, unless otherwise specified.

Referring now to FIG. 1, one embodiment of the assembler 10 is shown inbroad overview. In the embodiment shown, the assembler 10 is asingle-user workstation-type machine for assembling a carrier 14, whichis also a carrier for integrated circuits (see FIG. 4). The assembler 10includes a frame or support structure 16 which houses the necessarycomponents, as described below.

With reference to FIG. 4, the assembler 10 is used to assemble a carrier14 for printhead circuitry. The carrier 14 comprises an upper part 14.1and a lower part 14.2. The carrier parts 14.1 and 14.2 are typicallymolded from a liquid crystal polymer to define a plurality of tortuousprinting fluid paths therein. The carrier 14 is used to mount printheadintegrated circuits (not shown) for testing purposes.

The printhead integrated circuits is generally formed frommicro-electromechanical systems (MEMS) manufacturing techniques andcomprises a number of nozzle arrangements for operatively ejectingprinting fluids onto a medium. However, prior to installing theprinthead circuitry into a printer, it is important to test thecircuitry to ensure acceptable levels of operation. The carrier 14 isused as a conduit for the supply of printing fluids to the printheadcircuitry.

As shown in FIG. 4, the carrier 14 has an upper part 14.1 onto which thecircuitry is placed in operation. The upper part 14.1 defines a numberof openings for ducting printing fluid to similar openings of thecircuitry. The lower carrier part 14.2 defines a number of channelswhich form the fluid paths when the two parts 14.1 and 14.2 are bondedtogether. The assembler 10 is used to bond these parts together. Theassembler 10 uses a fastening apparatus in the form of a clamp assembly20, described below.

Referring now to FIG. 1, the assembler 10 includes the support bed 16which locates a lower clamp receptacle or nest 12 and an upper clampreceptacle or nest 18. A carriage assembly 26 is supported on thesupport bed and has a linear carriage defined by a rail 38 whichsupports, in a linearly displaceable manner, a first holding mechanism22 and a second holding or displacement mechanism 28, both linked anddriven by a linear actuator to be displaceable together along the rail38.

The first holding mechanism 22 includes a first gripper 24, and thedisplacement mechanism 28 includes a second gripper 30. In use, anoperator (not shown) is responsible for loading the assembler 10 withfour components, namely a lower clamp 20.1, an upper clamp 20.2, theupper carrier part 14.1 and the lower carrier part 14.2. The clampassembly 20 is shown in more detail in FIG. 9 discussed below.

In use, the operator loads the lower clamp 20.1 into the lower clampnest 12, and places the lower carrier part 14.2 into the lower clamp20.1. The upper carrier part 14.1 is placed into the first gripper 24 ofthe holding mechanism 22, and the upper clamp 20.2 is placed into thetop clamp nest 18.

The assembler 10 also includes an adhesive application apparatus havinga glue dispenser apparatus 32. The glue dispenser apparatus includes adispensing mechanism 34, a displacement mechanism 46, and an etchedplate 36. The dispensing mechanism 34 is configured to dispense anadhesive onto the etched plate 36. The etched plate 36 functions as anapplicator when a carrier part 14 is brought into contact with the plate36.

The assembler 10 further includes a control system or controller havingan operator interface in the form of a panel 42 and a touch-screendisplay 40. The operator interface is used to permit an operator tocontrol operation of the assembler 10. The control system also has abarcode scanner 44, which is used to scan identifiers in the form ofbarcodes from the clamp and carrier parts.

During operation of the assembler 10 and after the respective parts havebeen loaded into the different clamp nests and grippers, as describedabove, the process is as follows. Upon activation of the assembler 10via the operator interface, the mechanisms 22 and 28 are positioned asshown in FIG. 1. The glue dispenser 32 is activated so that thedispensing mechanism 34 is displaced across the etched plate 36 by thedisplacement mechanism 46, dispensing glue over the plate 36. Thedisplacement mechanism 28 then lowers the second gripper 30, which gripsthe upper carrier part 14.1 (FIG. 4), onto the etched plate 36.

The etched plate 36 has adhesive spread thereon by the action of thedispensing mechanism 34, so that dipping the upper carrier part 14.1therein coats a bottom surface of the carrier part 14.1 with adhesive.The second gripper 30 then raises the carrier part 14.1, whereafter thedisplacement mechanism 28 is displaced along the rail 38 so that thesecond gripper 30 can place the upper carrier part 14.1 onto the lowercarrier part 14.2. When the first holding and the displacementmechanisms 22, 28 are in a predetermined position, the first gripper 24and the second gripper 30 are lowered simultaneously.

The first gripper 24 retrieves the top clamp 20.2 from the top clampnest 18, whilst the second gripper 30 presses the upper carrier part14.1 onto the lower part 14.2 which is held by the bottom clamp in thelower clamp nest 12. Thereafter both grippers 24 and 30 are retractedupwards towards the rail 38, and the first holding and displacementmechanisms 22, 28 are moved so that the first gripper 24 is above thelower clamp nest 12. Once in position, the first gripper 24 locks thetop clamp 20.2 to the lower clamp 20.1, so that the carrier parts 14 areclamped together. This clamped assembly may then be subjected to a heatcuring process, or the like.

Prior to the operator loading the parts into their respective grippersand/or clamp nests, the parts 14 and clamps 20 can be scanned with thebarcode scanner 44. The barcode scanner 44 is in signal communicationwith the control system or controller of the assembler 10, which can beconfigured to log and keep track of discrete clamps and parts.

FIG. 2 shows a more detailed view of the lower clamp nest 12. The nest12 is affixed to the supporting bed of the structure 16 by means offasteners 54. In the embodiment shown, these fasteners are Allen screws,but any suitable fastener may be used. The nest 12 includes locatingtabs 52 to locate the lower clamp 20.1 therein, as well as proximitysensors 50 to sense when the clamp is correctly positioned and secured.In one embodiment the sensors 50 are short-barrel inductive proximitysensors. The sensors 50 are linked to the controller by means of wires56, as shown.

The Inventor has found that pre-wired miniature sensors from the Omron™E2E range are suitable for the sensors 50. The nest 12 also includes anorientation spigot 58 for complementarily engaging a correspondingaperture in the lower clamp 20.2 to ensure that the clamp is correctlyin position.

FIG. 3 shows a more detailed view of the top clamp nest 18. The nest 18is fastened to the support bed 16 with fasteners 66. In the embodimentshown, the fasteners are Allen screws, but any suitable fastener may beused. The nest 18 defines locating channels 60 for receiving the topclamp 20.2. The channels 60 include proximity sensors 62 linked to thecontroller by wires 64. The sensors 62 are used to sense when the topclamp is correctly in position. As above, the Inventor has found thatpre-wired miniature sensors from the Omron™ E2E range are suitable forsensors 62.

It is to be appreciated that sensors 50 and 62 are linked to thecontroller so that operation of the assembler 10 can be interrupted ifthe clamps are removed from the nests 12 and 18. For example, should thetop clamp 20.2 be accidentally or erroneously removed during operation,a safety system of the assembler (described in more detail below) mayinterrupt the assembler to prevent damage to components and/or injury tothe operator.

The adhesive dispenser apparatus 32 is shown in more detail in FIG. 5.As shown, the apparatus 32 comprises a dispensing mechanism 34 in theform of a glue cup or adhesive reservoir 34 with an accompanying gluecup lid 74 which is removable for refilling said cup with adhesive. Theglue cup 34 also includes a sealing member 76 which provides a reducedfriction surface to facilitate displacement of the glue cup 34 acrossthe etched plate 36.

The dispensing mechanism 34 is configured to dispense the adhesiveaccording to a pad printing technique. The glue cup 34 is displacedacross the plate 36 by the displacement mechanism 46, which includes apneumatic actuator sliding along a dispenser rail 70 actuated with airvia pneumatic tubing 72. The cup 34 is magnetically attracted to theplate 36 to form a tight seal.

The plate 36 includes an etched channel 68 which is shaped so that aparticular portion of the upper carrier part 14.1 is covered in gluewhen the second gripper 30 places said particular portion in the channel68. By displacing the glue cup 34 across the plate 36, a layer of glueis deposited on the plate and collects in the channel 68. The apparatus32 is controlled by the controller or control system described below.

The displacement mechanism 28 is shown in more detail in FIG. 6. Themechanism 28 is used to dip the upper carrier part 14.1 onto the etchedplate 36 of the glue dispenser 32, and subsequently to place the upperpart 14.1 onto the lower carrier part 14.2 held in the bottom clamp nest12.

The mechanism 28 has a micro-motor housing 80 housing a micro-motor toraise and lower the second gripper 30. This motor can include a DC motorwith precision screw mechanism to gently place and lift the carrier part14.1 onto the etched plate 36. The mechanism 28 can be configured tolift the carrier part 14.1 with an initial relatively slow movement toprevent “stringing” of the adhesive. The Inventor has found that theMaxon® 24V DC motor from the F2140 range is suitable for thisapplication. The motor typically includes safety switches to interruptpower to the mechanism 28 if it exceeds its normal extent of travel. TheInventor has found that two Cherry® sub-miniature DC1C-C3LC sealedswitches are adequate for this purpose.

The mechanism 28 also has actuator cylinders 82 to actuate the secondgripper 30. The cylinders 82 are connected to pneumatic components undercontrol of the controller via pneumatic connections 88. The cylinders 82include position sensors 86 to sense the position of the mechanism 28,which is relayed to the controller via wires 84.

A more detailed view of the holding mechanism 22 is shown in FIG. 7. Themechanism 22 includes the first gripper 24 and is attached to the rail38 of the carriage assembly 26. Actuator cylinders 90 are controlled bythe controller to actuate the first gripper 24 to retrieve and place thetop clamp onto the bottom clamp. The cylinders 90 are pneumaticallyoperated via pneumatic connections 92. The cylinders 90 can include aload cell (not shown) for measuring the amount of pressure applied whenthe top clamp is placed or pressed onto the bottom clamp. It is to beappreciated that the mechanism 22 generally applies a predeterminedamount of pressure to clamp the clamps 20 together.

Accordingly, the first gripper 24 includes clamp lock proximity sensors94 configured to determine when the clamps 20 are locked together.Typically, the clamps 20 have locking levers which are displacedproximate these sensors 94 when said clamps 20 are locked together. Thesensors 94 are operatively linked to the controller via wires 98. Thecylinders 90 can also include position sensors 96 to sense and relay theposition of the mechanism 22 to the controller.

An embodiment of the controller 100 is shown in FIG. 8, housed in anenclosure 102 of the assembler 10. The enclosure 102 houses the requiredelectrical and pneumatic components for operating the assembler 12. Thecontroller 100 includes a programmable logic controller (PLC). TheInventor has found that the Mitsubishi FX3U-48MR PLC is suitable. ThePLC generally includes an RS232 interface module (MitsubishiFX3U-232BD), and Ethernet interface module 104 (Mitsubishi FX3U-ENET)and a 2-channel analog function module (Mitsubishi FX3U-2AD).

The RS232 module is used to perform data transfer between the PLC 100and the barcode scanner 44. The RS232 module may also be used to upgradePLC software via an 8-way DIN connector. In general, the RS232 module isused to connect the PLC 100 with the display panel 40. A Monitouch®V606eC20 display has been found to be suitable, as it offers a 16-colour320×240 dots display incorporating an analog switch and a SRAM/built-inclock function. The Ethernet interface module 104 is used to connect thecontroller or PLC 100 to a remote monitoring system. The analog functionmodule is used to convert analog measurements from the load cell in theholding mechanism 22 into digital signals for interpretation by thecontroller 100.

The assembler 10 includes two DC power supply modules 110 and 116 forsupplying the PLC 100 and related components, along with a motorcontroller 114 and solenoid components discussed below, respectivelywith power. The Inventor has found that the Phoenix ContactMINI-PS-100-240 AC/24 DC/4 and MINI-PS-100-240 AC/5 DC/3, respectively,are suitable for the application.

The assembler 10 has a safety system, in accordance with an embodimentof the invention. The safety system includes an emergency cut offmechanism having two safety relays 134 in the form of a primary safetyrelay and a relay for a light curtain 150 (shown in FIG. 1) of thesafety system discussed in more detail below. The Inventor has foundthat the Wieland SNO 4003K Safety Relay is adequate for the primaryrelay, with the Omron G7S-4A2B DC24 Plug-In Safety Relay appropriate forthe light curtain relay. A flare relay 108 is also included between thepower supply 110 and the PLC 100, in the form of a Wieland 24V DCterminal relay.

A signal conditioning unit 106 is included which provides signalconditioning for the load cell in the holding mechanism 22. Gainselection and gross offset correction are allowed by this unit to matchload cell signals to input requirements of the PLC 100. An AppliedMeasurement RM044 unit has been found to be appropriate.

Overcurrent and earth leakage protection are provided by a Hager AD 810Tresidual current circuit breaker 130. The unit 130 is a single pole unitwith a switched neutral to detect sinusoidal residual current, andoffers earth fault detection and incorporates a trip free mechanism.

Ventilation and cooling for the enclosure 102 is provided by a Sunon 24VDC brushless fan 132. The fan unit 132 can include a filter to keep dustout of the enclosure 102.

The light curtain 150 forms a sensor arrangement and comprisestransmitter and receiver units located on opposite sides of the supportstructure 16 to create an invisible light curtain between the sides. Thesafety system, forming part of the control system includes a lightcurtain controller 136 that is configured to shut the assembler 10 downwhen a foreign object pierces the light curtain. The Inventor has foundthat a Keyence® SL-C32H Light Curtain is able to fulfill this task. Thelight curtain 150 is configured to interrupt electrical power and torelease air pressure in the pneumatic components when a foreign objectis detected.

The controller 100 is configured to regulate and control the pneumaticcomponents such as the grippers 24 and 30, the carriage 26, the gluedispenser 32, the mechanisms 22 and 28. To this end, and for safetypurposes, the enclosure 102 includes solenoid valves 120 and 112,pressure sensor 122, and isolation valve 126. For electrical protection,a number of fuses 118 and 128 are also included, as shown.

A side view of the enclosure 102 of FIG. 8.1 is shown in FIG. 8.2. Anair connector 140 is shown via which the assembler 10 is connected to anair supply for the pneumatic components controlled by the controller100. The connector 140 includes a pressure regulator 144 and the airsupply isolation valve 126 can be seen. The pneumatic connector 140includes a micro-mist separator to trap and drain moisture from anincoming air supply. A main AC power isolation switch 124 is alsoincluded.

As discussed above, the clamps 20 are shown in more detail in FIG. 9.The lower clamp 20.1 includes a bottom bar 151 with a silicone sheet152, which is attached to the bottom bar 151 by means of a rubberretainer 156 and retainer screws 158. Dowel pins 154 are also included,as shown. Clamp pins 160 are affixed to bottom bar 151 by means of pinnuts 162.

Accordingly, top clamp 20.2 has a top bar 164 having a glass layer 166attached to the bar 164 by means of glass clips 168 and clip screws 170.Clamp pin latches 172 operatively receive the clamp pins 160, whereafterthe second gripper 30 displaces dowel pins 174 outwards to lock theclamps 20 together. The top clamp 20.2 further includes cover 176 andcover screws attaching said cover 176 to the top bar 164, as shown.

FIGS. 10 and 11 show embodiments of the user interface panel 42 and afoot switch 192. The interface panel 42 includes a wipe button 180 whichis connected to the PLC 100 such that, on actuation, the controller todisplace the adhesive dispenser mechanism 34 across the etched plate 36to wipe excess glue from the plate 36. A reset button 182 is alsoprovided which resets the assembler 10 to a ready state. The interface42 includes two start buttons 184 and 188 as a safety feature. Boththese buttons 184 and 188 must be pressed simultaneously to activate theassembler 10. An emergency stop button 186 is also included, along witha scanner connection 190 for connecting the scanner 44 to the PLC 100.

In the embodiment shown, the foot switch 192 is used to instruct the PLC100 so that the upper carrier part 14.1 is gripped in the second gripper30, which frees up the operator's hands for the interface panel andtouch screen display 40.

The invention extends to a method 198 for assembling the carrier orcarrier 14 for the printhead circuitry. An overview of these methodsteps are shown in FIG. 12, individual steps generally represented bythe blocks referenced from numeral 200 to 240.

Blocks 204 and 220 refer to steps generally performed by the PLC 100transmitting data via the Ethernet module 104 to the remote monitoringsystem, such as a control network linked to a production or testingassembly, or the like. Steps indicated by blocks 200, 202, 206, 208,214, 212, 210, 216, 218, 222, 224, 226, 236 and 240 are generallyperformed by the operator. Blocks 228, 230, 232 and 234 represent stepstypically performed by the assembler 10 under control of the operator.

In preparation of bonding the carrier parts 14 together, the operatortypically commences the process 198 by retrieving the clamps 20 fromstorage, as indicated by block 200. The barcode scanner 44 is used toscan barcodes of the clamps (shown by block 202), and these barcodes aresent to the remote monitoring system during block 204.

The clamps 20 are then placed in their respective clamp nests 12 and 18located on the support bed 16 of the assembler 10. Similarly, thecarrier parts 14 are removed from a clean storage environment (shown inblock 212) and their barcodes are scanned in block 214, datarepresenting the barcodes being communicated to the remote monitoringsystem in block 220. The method can include the step of scanning a batchbarcode (block 222) of the parts and communicating data representing thebatch barcode to the remote monitoring system. The carrier parts 14 areloaded by placing the top carrier part 14.1 into the second gripper 30,and placing the bottom carrier part 14.2 into the bottom clamp 20.1 inthe bottom clamp nest 12 (blocks 208 and 224, respectively).

In anticipation of the bonding process, it might be necessary to fillthe glue cup 34 with glue prior to bonding. This process is shown byblocks 210 (retrieving the glue), 216 (scanning a barcode of the gluebatch), and 218 (filling the glue cup). Once the above steps have beencompleted, where necessary, the operator can press the start buttons 184and 188 (block 226) on the panel 42 to commence a process performed bythe assembler 10.

The PLC 100 then manages the steps of dipping the upper carrier part14.1 in the glue dispensed on the plate 36, and placing the upper part14.2 on the bottom part 14.2 (blocks 228 and 230, respectively). The topclamp 20.2 is retrieved by the first gripper 24, and pressed onto thebottom clamp 20.1 (block 232). The mechanism 22 then locks the clamps 20together, as described above, shown in block 234.

The operator is then able to remove the bonded and clamped assembly(block 236) from the bottom clamp nest 12, whereafter it can betransferred to a curing oven (block 240).

As mentioned above, the assembler 10 includes a safety systemrepresented by the respective sensors, described above, and the lightcurtain 150 as controlled by the PLC 100. The safety system monitors anoperating zone within the support structure 16, generally as demarcatedby the light curtain 150. If a foreign object is sensed by the lightcurtain, or any sensor senses an undesired position of a mechanism, thePLC 100 deactivates the assembler 10.

Accordingly, the PLC 100 is configured to deactivate the assembler whenany undesirable operational status, as monitored by the PLC 100, isdetected. The PLC 100 generally monitors positions of the movablemechanisms, such as mechanisms 22 or 28, carriage 26, glue dispenser 32,gripper 24 and 30, etc. The fluid pressure of the pneumatic components,as described above, is also monitored. Similarly, the presence andcorrect placement of the carrier parts and clamps 20 in their respectivenests or grippers can be monitored, along with the authenticity of thecomponents as identified by their barcodes.

As discussed above, the PLC 100 also monitors the electricity supply tothe assembler 10. In one embodiment, the operator may have to provideidentification prior to operating the machine. This may include keyingin a code via the display 40, or the like. Should any of the monitoredaspects not be complied with, the PLC 100 can be programmed not toactivate the assembler 10. Accordingly, the PLC 100 can be connected toany suitable sensors for monitoring the above aspects, such as pressuresensors, proximity sensors, etc.

The above examples are merely to guide the skilled person inimplementing the invention, and are not meant to unduly restrict thescope thereof. It is to be appreciated that any reference to particularcomponents specific to particular manufacturers does not limit theinvention to the use of these components. As such, the skilled personwill appreciate that similar functionality is achievable by differentcomponents or even different configurations without detracting from thescope of the invention.

1. An assembler for assembling a carrier for supporting printheadintegrated circuits, said carrier having upper and lower parts that areoperatively fastened together, said assembler comprising: a supportstructure configured to support the lower part in a pre-fastenedposition; a holding mechanism arranged on the support structure forholding the upper part in a pre-fastened position; a displacementmechanism arranged on the support structure for displacing the holdingmechanism relative to the support structure to bring the parts intooperative registration with each other; and a fastening apparatus forfastening the parts together.
 2. An assembler as claimed in claim 1, inwhich the support structure has a support bed and a carriage assemblypositioned on the support bed, the displacement and holding mechanismsbeing arranged on the carriage assembly.
 3. An assembler as claimed inclaim 2, in which the carriage assembly has a linear carriage spacedfrom the support bed and carriage actuators for linear displacement ofthe holding and displacement mechanisms with respect to the support bed.4. An assembler as claimed in claim 3, in which the fastening apparatusincludes an operatively lower clamp and an operatively upper clamp, theclamps being configured to correspond with the lower part and the upperpart respectively to clamp the parts together, the support bed beingconfigured to support the lower clamp in a pre-clamped position.
 5. Anassembler as claimed in claim 4, in which the fastening apparatusincludes an upper clamp lifting and holding mechanism arranged on thecarriage assembly and configured to lift the upper clamp from thesupport bed and to bring it into operative engagement with the lowerclamp.
 6. An assembler as claimed in claim 4, in which the fasteningapparatus includes an adhesive dispenser arranged on the supportstructure and configured to dispense an adhesive to be applied to one ofthe parts.
 7. An assembler as claimed in claim 6, in which the fasteningapparatus includes an adhesive applicator positioned on the support bedto receive adhesive dispensed by the dispenser, the displacementmechanism being configured to displace the upper part into engagementwith the applicator prior to positioning the upper part on the lowerpart.
 8. An assembler as claimed in claim 7, in which the upper clamplifting and holding mechanism is configured to bring the upper clampinto operative engagement with the lower clamp subsequent to positioningthe upper part on the lower part.